Method of connecting rigid bodies and rigid body

ABSTRACT

A method for constructing a rigid structure, such as a bullet-resistant structure, includes the provision of a first panel having an opening. A second panel is provided and has a tab extending therefrom. The tab of the second panel is inserted into the opening of the first panel. The first panel is fixed to the second panel only in an area of the opening. In this manner the mechanical properties of the first and second panels are not considerably effected by the fixing process.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No. 10/744,485 filed Dec. 23, 2003, which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

The invention relates generally to a method of constructing a body and more specifically to constructing a rigid body or a rigid volume.

The current trend in the armoring industry is to build fixtures using plates in which the materials used cannot be mechanically modified more than a certain percentage. Mechanical modification usually occurs partially or totally at the connection points or edges between adjacent panels. Usually the properties are changed because of the transformation of the properties of the materials themselves due to the changes in the crystal and grain matrix of the material because of the bonding method such as welding. For example, the heat from the welding process changes the mechanical/chemical properties of the panels being welded together and therefore critically changes the properties (e.g. weakens) of the panels.

A prior art solution is to forgo the welding process but requires the use of additional components for interconnecting the armored pieces. However, this results in added weight, additional components and complexity to the original body under construction. The increase in the number of parts requires increased manufacturing and installation costs and also increases the probability of failure in a system with the ever-increasing number of parts. In addition, the added weight has an impact on driveability should the structure be a vehicle and the need for a reinforced frame for bearing the extra weight.

An armored system acts as a fuse and is configured for absorbing significant amounts of energy from projectiles impinging on the armored components. The armored system modifies its own shapes and sometimes its properties while absorbing the energy. Therefore structures assembled with armor plating cannot be tested individually but by statistical testing so that a confidence in prediction based upon results of the tests satisfies the requirements. In this way the real level of quality of the armored structure depends on the quality of the armored plates and the modification or their properties while being treated and/or assembled. Therefore, the armored plating that is the least handled and modified is the most reliable as its properties is the least changed during assembly (e.g. subjected to welding heat).

SUMMARY OF THE INVENTION

It is accordingly an object of the invention to provide a method of connecting rigid bodies and a rigid body that overcome the above-mentioned disadvantages of the prior art devices and methods of this general type, which provides better mechanical properties without increasing assembly time and complexity.

With the foregoing and other objects in view there is provided, in accordance with the invention, a construction method. The method includes providing a first panel having an opening formed therein, providing a second panel having a tab extending therefrom, inserting the tab of the second panel into the opening of the first panel, and fixing the first panel to the second panel only in an area of the opening.

In accordance with an added feature of the invention, the first and second panels are bullet-resistant and/or armored panels.

In accordance with an additional feature of the invention, the panels are fixed to each other by welding, gluing, melting and/or fusing.

In accordance with a further feature of the invention, additional panels having the slot and tab connectivity are added for forming a self-contained bullet-resistant structure. Such a structure is used for protecting an automobile, building, other vehicles, etc.

In accordance with another feature of the invention, the opening may take many different types of shapes such as rectangular shapes, square shapes, slot shapes, oval shapes, circular shapes and triangular shapes. The critical feature being that the shape must be conducive to the fusing process. The fusing may be performed only on one side of the first and second panels. Alternatively, the fusing is performed on both sides of the first and second panels. Contrary to the prior art, the ability to fuse the panels in multiple areas provides increased strength. Ideally, the tabs and slots take up less than 50% of the width of the panel and preferably less than 35%. As the spacing between the slots increases, the change to the mechanical properties of the panels decreases. However, the degree of spacing is also limited by the desired structural integrity.

In accordance with another further feature of the invention, the edges, margins or perimeter of the panels are shaped to form a form-locking connection when the edges overlap each other. Because of the shaped edging, changes to the mechanical properties of a panel in a given area is limited as the direction of the fusing, welding, gluing, etc. changes following the pattern of the shaped edge. In this manner, additional panels may be added and connected to each other by either the slot and tab technique or by form-locking connections in dependence on how the panels are interconnected.

Ideally, the panels are formed of metals, plastics, glass, composites and acrylic resins.

In accordance with a concomitant feature of the invention, the edges have a square wave shape, a dove-tail shape, and/or a tongue and groove type shape. The critical features are that a form-locking connection is formed and that a direction of the shaped edges changes as one traverses the panel so that a fusing line is not straight.

Other features which are considered as characteristic for the invention are set forth in the appended claims.

Although the invention is illustrated and described herein as embodied in a method of connecting rigid bodies and a rigid body, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic, exploded, perspective view of two panels to be connected according to the invention;

FIG. 2 is a diagrammatic, perspective view after the connection of the two panels;

FIG. 3 is a diagrammatic illustration of the interconnection of three panels according to the invention; and

FIG. 4 is a diagrammatic illustration equivalent to FIG. 3 but highlights a second panel for better comprehension.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the figures of the drawings in detail and first, particularly to FIG. 1, thereof, there is shown a first armored panel 1 having a slot 2. A second armored panel 3 has a protrusion or tab 4 that has been precisely cut to fit into the slot 2. The invention teaches a method of interlocking and mechanically fixing the panels 1, 3 to each other by use of the precision cut tab 4 and the slot 2. The tab 4 of the second armored panel 3 is inserted into the slot 2 of the first armored panel 1. Once the tab 4 is inserted into the slot 2, the second armored panel 3 has mechanical resistance to stresses from every direction but an insertion direction 5 defined by a main axis of the slot 2. Analogously, the first armored panel 1 has the same stress properties.

Because of the assembly method, the mounted panels 1, 3 have significant resistance to the main stress points. The added strength needed to withstand cycles of vibration is obtained by fusing completely or partially the inserted tab 4 with the receiving slot 2. Since an area 6 to be fused is a limited area defined by the slot 2, modification of the mechanical properties of the first and second panels 1, 3 is limited in the worst case to the area 6. The tab 4 can be fused to the slot 2 by gluing, welding, melting, etc. The fusing method of course is dependent on the material(s) of the panels 1, 3 (e.g. metal, glass, acrylic resin, polycarbonate, plastics, etc.) and on the use of the panels. It is noted that the fusing can be done on both sides of the panel if desired and is not restricted to one side or the other side. It is noted that the panels shown in FIGS. 1 and 2 are exaggerated in the sense that the tab 4 and slot 2 are shown as taking up a good portion of the panels 1, 3. In reality, and as better shown in FIGS. 3 and 4, the area necessary for the slots and tabs is small.

In addition, the absence of extra parts, such as brackets, to assemble the armored assembly formed of the panels 1, 3 ensures a minimum weight and reduces the chances of system failure (e.g. less parts).

In FIG. 3, three panels 11, 12, 13 are assembled according to the invention. The third panel 13 is connected to the first panel 11 using the slot and tab technique taught in regards to FIGS. 1 and 2. It can be seen from FIG. 3 that the slots 2 and tabs 4 require a small surface area. FIG. 4 is equivalent to FIG. 3 with the exception that panel 13 is shown colored for better identification.

All of the panels 11, 12, and 13 may additionally be formed with intricate edging 14. More specifically, the edges have a dovetail or square wave type interconnection. When the two panels 11, 12 are place next to each other, the edgings 14 interlock with each other. The edgings can then be fused to each other by welding, melting or an adhesive, depending on the material forming the panels 11, 12, 13. Like in the first embodiment, the edging 14 provides resistance in the main stress directions and can be further connected by fusing for absorbing vibration forces.

In FIGS. 3 and 4 the edgings have a square wave shape. However, the edging can have any interlocking type shape such as dovetail shaping. The critical feature is that a form-locking connection is formed between the panels 11, 12, 13. A form-locking connection is one that connects two elements together due to the shape of the elements themselves, as is opposed to a force-locking connection, which locks the elements together by a force external to the elements. For example a nut and bolt holding two elements together is a force-locking connection because of the external force provided by the nut and bolt. In contrast, a ball and socket are held together because the shapes of the ball and socket interconnect with each other and provide the connection without the application of an external force. 

1. A construction method, which comprises the steps of: providing a first panel having an opening formed therein; providing a second panel having a tab extending therefrom; inserting the tab of the second panel into the opening of the first panel; and fixing the first panel to the second panel only in an area of the opening.
 2. The method according to claim 1, which further comprises forming the first and second panels as bullet-resistant panels.
 3. The method according to claim 1, which further comprises performing the fixing step by one of welding, gluing, melting and fusing the first and second panels together.
 4. The method according to claim 2, which further comprises providing and connecting additional first and second panels for forming a self-contained bullet-resistant structure.
 5. The method according to claim 1, which further comprises forming the opening to have a shape selected from the group consisting of rectangular shapes, square shapes, slot shapes, oval shapes, circular shapes and triangular shapes.
 6. The method according to claim 3, which further comprises performing the fixing step only on one side of the first and second panels.
 7. The method according to claim 3, which further comprises performing the fixing step on both sides of the first and second panels.
 8. The method according to claim 1, which further comprises shaping edges of the first and second panels such that the panels form a form-locking connection when the edges overlap each other.
 9. The method according to claim 8, which further comprises: providing a third panel having edges shaped for forming a form-locking connection; placing the third panel adjacent the first panel such that the edges of the first and third panel interlock; fusing an edge area between the first and third panels defining the form-locking connection.
 10. A bullet-resistant structure, comprising: a first bullet-resistant panel having an opening formed therein; and a second bullet-resistant panel having a tab received and disposed in said opening of said first panel, said first panel being further fixed to said second panel only in an area of said opening.
 11. The bullet-resistant structure according to claim 10, wherein said first and second panels are fused to each other only in the area of said slot, the first and second panels being fused to each other by a method selected from the group consisting of welding, gluing, and melting.
 12. The bullet-resistant structure according to claim 10, wherein said first and second panels are formed of a material selected from the group consisting of metals, plastics, glass, composites and acrylic resins.
 13. The bullet-resistant structure according to claim 10, wherein said opening has a shape selected from the group consisting of rectangular shapes, square shapes, slot shapes, oval shapes, circular shapes and triangular shapes.
 14. The bullet-resistant structure according to claim 11, wherein said first and second panels are fused to each other only on one side of said first and second panels.
 15. The bullet-resistant structure according to claim 11, wherein said first and second panels are fused to each other on both sides of said first and second panels.
 16. The bullet-resistant structure according to claim 11, wherein: said first panel is one of a plurality of first panels; and said second panel is one of a plurality of second panels, said first and second panels are interconnected to each other for forming a self-sustaining structure.
 17. The bullet-resistant structure according to claim 11, wherein said first and second panels have edges shaped such that said edges form a form-locking connection when said edges overlap each other.
 18. The bullet-resistant structure according to claim 17, further comprising a third panel having edges shaped such that said edges form a form-locking connection with said edges of said first and second panels, said third panel forming the form-locking connection with one of said first and second panels.
 19. The bullet-resistant structure according to claim 18, wherein said edges are fused to each other by a process selected from the group of welding, gluing, and melting.
 20. The bullet-resistant structure according to claim 18, wherein said edges have a shape selected from the groups consisting of a square wave, a dove-tail, and tongue and groove. 